Wire splice



2 Sheets-Sheet 1 INVENTOR.

n ATTORNEYS `Maly 14, 1968 J. A. NAVA ETAL WIRE SPLICE Filed Sept. 2, 1965 May 14, 968

J. A. NAVA ETAL WIRE SPLICE 2 Sheets-Sheet ,'f

Filed Sept.

S Y www www 45e. HF, Jaw@ United States Patent O 3,383,642 WIRE SPLICE Joseph A. Nava, Villa Park, Jack F. Shearer, Lake Forest,

and Alvin R. Burton, Northbrook, Ill., assignors to The Pyle-National Company, Chicago, Ill., a corporation of New Jersey Filed Sept. 2, 1965, Ser. No. 484,657 1 Claim. (Cl. 339-205) ABSTRACT F THE DISCLOSURE A cylindrical wire splice device having an internal metallic connector portion formed by rolling a pre-cut metal strip, and an insulating cover rolled about the connector portion to insulate the electrical contact of the connector portion from points external of the device. The ends of the wires to be spliced have a radially enlarged collar which is engaged between oppositely axially directed tines of the connector portion to iixedly position the ends of the wires within the device. Gripping surfaces at the center of the connector portion rigidly grip the ends of the wires to form a proper electrical contact therebetween. The ends of the insulating cover have resilient plug members which are inserted therein to seal the wires both before and after insertion into the device. The plug members have an opening to allow the insertion of the wires therein, and a portion of the plug member extends across the opening to seal the interior of the connector portion in the absence of wires being inserted into the device.

This invention relates in general to quick operating wire splicing devices and in particular to a splicing device wherein wire ends are provided with male contacts and are electrically connected together in either a cornmon interconnected splice or in separate individual splices and wherein the wires are connected and retained in position by a formed metal strip which acts not only as an electrical socket but as a mechanical retention coupling.

This invention also relates to a method of making a lsplice device with regard to a common splice between a plurality of wires or to separate individual connections between the wires.

In applications where there is a requirement to form a detachable connection between two wires or between a group of wires, such connections between single pairs of wires or between respective wire groups can be formed by providing a standard type of connector having male and female components. With an end of one wire group soldered to the male connector portion and an end of the other wire group `soldered to the female connector portion the respective wire groups can be connected by engaging the male portion with the female portion in a manner well known in the art.

However, the present invention is particularly useful where it is desired to `form a common splice between a multiplicity of wires without resorting to relatively expensive connectors and cumbersome interconnections, and where the splicing device can quickly connect and disconnect the wires.

To form a common connection between a number of wires connected by the ystandard type of male-female connectors previously described requires a laborious procedure to electrically interconnect each of the contacts thereof. Usually this would be accomplished by using jump wires soldered between the contacts of the desired wires to be spliced in common. This procedure is not only time consuming and inetlicient, but it results in a cumbersome and bulky connection.

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It is therefore an object of the present invention to provide a quick connect and disconnect wire splicing device.

Another object of this invention is to provide a wire splicing device which is readily adapted for connecting a plurality of wires in a common splice or in individual and separate splices.

A further object of this invention is to provide a method of making a wire splicing device.

Other objects and advantages will be apparent to those versed in the art upon making reference to the description which follows and the accompanying sheets of drawings in which a structural embodiment of the invention is shown by way of example and from which the methods of the present invention may be understood.

As shown on the drawings:

FIGURE 1 is a development of metal strip prior to forming and used in making the splice device according to the principles of the present invention;

FIGURE 2 is a cross-sectional view of the metal strip of FIGURE 1 after it has been formed by rolling into a generally cylindrical form;

FIG-URE 3 is a sectional view taken along the line III-III of FIGURE 2 and illustrating the spring-like gripping surface forming the spliced connection;

FIGURE 4 is a sectional view of a wire splice device constructed in accordance with the principles of the present invention and incorporated to form a connection between a single pair of wires;

FIGURE 5 is a sectional view taken along the line V-V of FIGURE 4;

FIGURE `6` is a sectional view of a multiple splicing device which can be utilized to form a common splice between two pairs of wires or to form two separate and individual splices between corresponding pairs of wires;

FIGURE 7 is a Sectional view taken along the line VII-VII of FIGURE 6;

FIGURE 8 is a sectional view taken along the line VIII-VIII of FIGURE 6A with the outer insulating cover removed to illustrate a bridged interconnection;

FIGURE 9 is a sectional -view similar to the illustration of FIGURE 7 and showing the principles of the invention incorporated in an alternative multiple splicing device with bridged interconnections;

FIGURE l0 is a sectional view of the splicing device illustrated in FIGURE 9 with the outer insulating cover removed; and

FIGURE 11 is a sectional view illustrating a splicing device capable of separately `and individually splicing corresponding pairs of a desired multiple wire group.

As shown on the drawings:

The present invention contemplates a splicing device wherein the principles of construction may be utilized to provide a single splice between a single pair of wires, a common splice between `a multiplicity of paired wires, or .a multiplicity of single wire spliccs between corresponding paired wires.

According to one aspect to this invention an electrical connection between the wires is provided by a formed electrically 4conductive metal strip which `also acts to retain the wires in position. When a plurality of such strips is provided they can be bridged together to form a common splice between a number of wires, or the strips can be utilized as separate individual pieces to form multiple single wire splices.

Referring now to FIGURE l, there is shown :a flat metal strip 10` which forms the basic connecting land retaining portion of the wire splicing devices to be described herein. The metal strip 10 is formed with a series of inner tines 12 and a pair of outer tines 14 at each of the strip ends 16. The outer tines 14 are utilized to resiliently grip d@ the wire ends to be spliced so as to maintain the wires in position within the splicing device. The inner tines 12 prevent the wires from projecting too far into the splicing device.

4Between the ends 16 of the metal strip 10 there is formed a connector or socket portion 18 which is defined by four cutouts 20 which extend from a wide mouth or piloting portion 22 at each of the strip edges 24 to a narrow dead end 26. A pair of longitudinal slits 28 eX- tend from the strip edge 214 into the connector portion 18. At each of the strip ends 16 and on one side of the metal strip 10 there is formed a projecting rib 30 which is shaped so as to mate with ia similarly dimensioned groove 32 on the strip edge 24 at the opposite side of the metal strip 10.

In FIGURE 2 the flat metal strip 10 is shown after it has been rolled to form the ends 16 into generally cylindrical shape with the inner tines 12 projecting into the -center thereof and away from the connection portion 18; and the outer tines 14 also projecting into the center thereof but towards the connection portion 18. It may be noted that in the rolled position of the strip 10 shown in FIGURE 2 lthe lip 50 on each of the ends 1d is engaged within the groove 32 to maintain the rolled strip in alignment.

Referring to FIGURES 2 and 3, it can be seen that the connector portion 18 is rolled into a resilient configuration including opposite gripping surfaces 34. The resilient gripping surfaces 34 .are provided toI grip around the ends of the wires to be spliced so as to form an electrical connection between the wires.

Referring to FIGURES 4 and 5, there is illustrated a wire splicing device which incorporates the principles of the present invention in a splicing device capable of quickly interconnecting a single pair of wires. A tubular outer insulating cover 42 has a g-enerally hollow center 44 within which there is held a rolled metal strip 46 formed similar to the rolled strip shown in FIGURE 2. The metal strip 46 includes a connector portion 18 which forms a splice between a pair of wires 48 each having a connector contact on the wire ends to be spliced. The connector contact 50 is a standard type of male connector contact which is crimped onto the ends of the wires 48. At each end of the wire splice device 40 there is provided a molded rubber end seal 52 which is bonded to the outer insulating cover 42.

The splice is formed by inserting the respective wire 48 `and contact 50 through the end seal 52. until a collet 54 is intermediate the inner tines 12 and the outer tines 14. In this position the resilient opposite surfaces 34 tirrnly grip the connector contacts 50 since the contacts 50 have a diameter slightly larger than the diameter between the arcuate sections forming the gripping surfaces 34. This insures a firm electrical contact between the wires 48 which are thereby spliced. Further, the shank end 56 of the contact 50 is rmly held in position by the tines 14 pressing on the surface of the shank 56. The opposite slanting directions of the inner tines 12 and the outer tines 14 maintain the collet 54 and thereby the contact 50 to the desired position within the splicing device 40.

The splicing device 40 is constructed by forming a hat metal strip 10 as shown in FIGURE 1, with the connector portion 18 dimensioned to suit the desired connector contact 50. The flat strip 10 is then rolled to rform a rolled metal strip 45 similar to that shown in FIGURE 2 so as to Iprovide a pair of arcuate sections 58 having opposite gripping surfaces 34. The dimension of the connector portion 18 is chosen so that the diameter of the arcuate section 58 is slightly less than the connector contact 50, A flat piece of dielectric material such as polysulfon is first molded and then wrapped around the rolled metal strip 45. The abutting faces e0 of the insulating cover 42 are then bonded to complete the construction.

Referring to FIGURES 6, 7 and 8, there is shown a wire splicing device 70 which is used to interconnect in a common splice a double pair of wires. The splicing device 70 is formed with an insulating cover 72 and end seals 74 bonded to each end of the insulating cover 72. rl`wo rolled metal strips 76 are located within two separate chambers 78 defined within the insulating cover 72. The rolled metal strips 76 are formed similar to the strips previously described with the inside tangs 80 and the outside tangs 82. A bridging connection 84 is provided between the two strips 76 to form a common splice between a double pair of wires respectively inserted into the splicing device 70 through the end seals 74 so as to be resiliently held between the arcuate sections 86. The wires and the corresponding connector contacts are maintained within the splicing device 70 by the outer tangs 82 which firmly grip the contact. The connector contact and the associated wires have not been illustrated in FIGURE 6 since this would simply be a repetition in multiple of the illustration in FIG- URE 4.

If separate individual splices are required between respective pairs of wires, the bridging connection j84 can be eliminated. The multiple splicing device 70 is similarly formed as the single splice device with the insulating cover 72 formed around the 'bridged rolled strips 76 and the construction completed `by bonding the abutting faces 88.

Referring to FIGURES 9 and 10, there is shown a multiple splicing device which can be utilized to form a common splice between three pairs of wires or separate individual splicers can also be provided. In this configuration an insulating cover 92 is formed around three rolled metal strips 94 which are located in three separate generally cylindrical chambers 96. The rolled strips 94 have arcuate sections 98 to form a reliable connection with the desired connector contacts and associated wires. Each of the rolled strips 96 is interconnected with a bridging connection 100 to form a common splice between three pairs of wires inserted respectively into each of the rolled strips 96.

In FIGURE l1 there is shown an alternative embodiment of the multiple wire splicing device 90. In this embodiment a wire splicing device 102 includes an outer insulating cover 104 wherein there is defined three generally cylindrical and electrically insulated chambers 106. Within each of the chambers 106 there is provided a rolled metal strip 108 similar to the strips previously described but with the bridging connection 'being eliminated. The insulating cover 104 of dielectric material has three projecting legs 110 which extend between each of the metal strips 108 so as to provide an insulation therebetween. The three projecting legs 110 are bonded together to form a longitudinal bonded inner joint and thereby insure dielectric separation between the strips 108. If desired, a common splice can be formed between two of the metal strips 108 with the remaining strip 108 providing a separate and individual splice.

Although various modifications might be shown 'by those versed in the art, it should be understood that we wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of our contribution to the art.

We claim:

1. A wire splicing device for splicing wires terminated in a standard male connector contact,

a longitudinally split tube made of electrically conductive spring metal and forming a current continuing member,

the confronting longitudinal edges of said split tube having a pair of spaced cut-outs dividing the tube into a central socket portion and separate retainer portions at opposite ends,

said central socket portion being offset radially inwardly to form reduced confronting curved gripping surfaces or mechanically' and electrically engaging a male connector contact inserted into either respective end thereof, each said retainer portion being of a generally cylindrical configuration and having spaced tines struck out from the walls thereof and extending inwardly of said retainer portion to lock the male connector Contact in place, and a generally cylindrical insulating cover enclosing said split tube,

said cover having a resilient end seal in each respective end of said cover for sealably engaging a corresponding splicing Wire inserted thereinto.

References Cited UNITED STATES PATENTS 2,463,826 3/1949 Thacker 339-1948 2,533,200 12/1950 Rogoif 339-223 Doane 339-91 Chickvary 174-93 Hubbell 339-111 XR Olson et al. 339-111 XR Bowen 339-217 Neaderland 174-93 XR Kohler 174-93 Douglas 339-217 X Ruskin 174-88 Richards 339-205 X Zimmerman, et al. 339-217 RICHARD E. MOORE, Primary Examiner.

DARRELL L. CLAY, MARVIN A. CHAMPION,

Examiners.

P. A. CLIFFORD, Assistant Examiner. 

